Process for the polymerization and/or copolymerization of olefins with the use of ziegler-type catalysts supported on carrier

ABSTRACT

A PROCESS FOR POLYMERIZING AND/OR COPOLYMERIZING OLEFINS BY USING AN IMPROVED CATALYST CONSISTING OF A TRANSITION METAL COMPOUND SUPPORTED ON ELECTRONDONOR-PRETREATED INORGANIC SOLID PARTICLES TE TRANSITION METAL COMPOUND BEING A COMPONENT OF A ZIEGLER-TYPE CATALYST, AND AN ORGANOMETALLIC COMPOUND, WHEREBY THE POLYMERIZATION ACTIVITY OF THE CATALYST PER UNIT WEIGHT BOTH OF THE TRANSITION METAL AND ORGANOMETALLIC COMPONENT REMARKABLY INCREASES, THUS MAKING IT POSSIBLE TO REDUCE AN AMOUNT OF A CARRIER WHCH REMAINS IN THE RESULTANT POLYMER CAUSING INCREASED ASH CONTENT, AND ALSO POSSIBLE TO EASILY CONTROL THE MELT-INDEX OF THE RESULTANT POLYMER.

"United States Patent US. Cl. 260-882 12 Claims ABSTRACT OF THE DISCLOSURE A process for polymerizing and/ or copolymerizing olefins by using an improved catalyst consisting of a transition metal compound supported on electrondonor-pretreated inorganic solid particles the transition metal compound being a component of a Ziegler-type catalyst, and an organometallic compound, whereby the polymerization activity of the catalyst per unit weight both of the transition metal and organometallic component remarkably increases, thus making it possible to reduce an amount of a carrier which remains in the resultant polymer causing increased ash content, and also possible to easily control the melt-index of the resultant polymer.

This invention relates to a process for polymerizing or copolymerizing olefins by using an improved catalyst consisting of a transition metal compound supported on inorganic solid particles, the transition metal compound being a component of a Ziegler-type catalyst, and an organometallic compound, whereby the polymerization activity of the catalyst per unit weight both of the transition metal and of the carrier-supported catalyst component remarkably increases, thus making it possible to reduce the amount of carrier which remains in the resultant polymer and causes a high ash content, and also easily control the melt-index of the resultant polymer. More particularly, the invention relates to a process for polymerizing or copolymerizing olefins in the presence of a catalyst comprising Ziegler-type catalyst components supported on inorganic solid particles, which process comprises polymerizing or copolymerizing olefins in the preence of a catalyst comprising (1) a transition metal compound supported on inorganic solid particles, obtained by pre-treating solid particles of a dihalide of a divalent metal selected from the group consisting of magnesium, calcium, zinc, chromium, manganese, iron, cobalt and nickel with an electron donor selected from the group consisting of aliphatic carboxylic acids, aromatic carboxylic acids, alkyl esters of aliphatic carboxylic acids, alkyl esters of aromatic carboxylic acids, aliphatic ethers, cyclic ethers, aliphatic ketones, aromatic ketones, aliphatic aldehydes, aliphatic alcohols, aromatic alcohols, aliphatic acid halides, aliphatic nitriles, aromatic nitriles, aliphatic amines, aromatic amines, aliphatic phosphines and aromatic phosphines which is liquid or gaseous under the pre-treating conditions, in the substantial absence of water, and then heating said pre-treated solid particles together with a halogen compound of a transition metal selected from the group consisting of tetravalent titanium, tetravalent vanadium and pentavalent vanadium metal which is liquid under the heat-treatment conditions to thereby bond said halogen compound to the surfaces of said pretreated solid particles; and,

3,642,746 Patented Feb. 15, 1972 "ice (2) an organometallic compound selected from the group consisting of organoaluminum compounds and alkyl zinc.

Ziegler-type catalysts for polymerizing olefins which consist of transition metal halogen compounds and organometallic compounds are generally known. There has, however, been a tendency that the catalyst components are agglomerated in the polymerization system and as a result, only the surface of the agglomerated mass acts as the catalyst and those particles inside the mass are consumed uselessly. Various proposals have therefore been made to prevent the agglomeration of the catalyst particles by supporting them on a carrier and to use the catalyst effectively.

As such proposals, the use of a Ziegler-type catalyst bonded to the surfaces of finely divided particles of a carrier has been known (for instance, British Pat. 841,822, British Pat. 1,024,336, Belgian Pat. 705,220, and US. Pat. 3,166,542). Since, however, residue of a solid matter in the resulting polyolefin is undesirable for some applications, there has been a demand for catalysts wherein the carrier can be easily removed from the resultant polyolfin after the completion of the polymerization. In the regard, there was a proposal in US. Pat. 3,288,720 corresponding to British Pat. 927,969 in which a compound soluble in water or alcohol is used as a carrier, and after the completion of polymerization, it is removed by washing with water or alcohol.

According to this proposal, a catalyst is used for the gaseous phase polymerization of olefins prepared by reacting an organometallic compound impregnated into a carrier with a transition metal compound, and combining the reaction product with an organometallic compound. The patent discloses, for instance, calcium carbonate, calcium chloride, or sodium chloride as a preferred carrier. The catalyst prepared by this method, however, does not have outstanding high activity of polymerizing olefins, and has a drawback that it requires a greater quantity of the carrier. As a result, much ash content attributable to the carrier remains in the resultant polyolefin unless it is treated with water or alcohol after completion of the polymerization reaction, and such ash content gives adverse eflects to the properties of the polymer. For instance, it is likely that shaped articles made from the polymer will undergo occurrence of fish eyes, yarn breakage, coloration, or undesirable interaction with an additive (such as stabilizer, mold-releasing agent, and coloring agent), and such defects constitute substantial restrictions on the use of the polymer. For minimizing such restrictions, the polymer produced according to this proposal must be subjected to complicated and disadvantageous post-treatments to remove the carrier.

We attempted at developing a polymerization catalyst system which is rendered very highly active in polymerization by using a carrier and in which the amounts of the catalyst and carrier are small enough to require no posttreatment of the resulting polymer and if desired, the carrier can be easily removed by a simple treatment with water or alcohol. It has now been found to our surprise that a polymerization catalyst having an exceedingly improved activity per unit weight both of the carrier-supported catalyst and of transition metal can be obtained by pre-treating solid particles of a dihalide of a divalent metal selected from the group consisting of magnesium,

calcium, zinc, chromium, manganese, iron, cobalt and As the inorganic material, magnesium dihalidesand manganese dihalides, but magnesium dichloride and manganese dichloride are preferred. It has also been found that the improvements contemplated by this invention cannot be obtained with a mere conjoint use of a Zieglertype catalyst and an electron donor without a carrier, but also with the use of a catalyst obtained by supporting a Ziegler-type catalyst on a metal halide in the presence of an electron donor without prior treatment of the metal halide, or with the conjoint use of a small amount of an electron donor and a conventional carrier-supported catalyst without prior electron donor treatment. We have also found that a considerably wide variety of compounds can be used as the electron donor to be used in the pretreating of a carrier according to the invention, and the process is commercially very advantageous in this respect, too.

' Accordingly, an object of this invention is to provide a process for the preparation of polyolefins using a Zieglertype catalyst supported on a dihalide of a divalent metal as a carrier which has an improved polymerization activity per unit weight of the supported catalyst over conventional supported catalysts of this kind and therefore reduces the ash content of the resulting polymer attribut able to the carrier.

Many other objects and advantages of the invention will become more apparent from the following description.

The transition metal halogen compounds, organoaluminum compounds or dialkyl zinc used as the catalyst in the invention are known per se as the components of Ziegler-type catalysts.

The dihalides of divalent metals used as the carrier of the transition metal halogen compounds are insoluble or sparingly soluble in inert solvents used in the polymerization reaction of olefins, are readily soluble in water, and do not adversely affect the polymerization catalysts. Specifically, they are a dihalide, preferably a chloride, bromide or iodide, of a divalent metal selected from the group consisting of magnesium, calcium, zinc, chromium, manganese, iron, cobalt and nickel. Such carriers are used in the form of anhydride commercially available, or when they contain water of crystallization, they may be used after heating in a stream of a halogen corresponding to the respective dihalide.

The particle size of the metal halide used as carrier in the invention may be, for instance, in the range of 0.05 to 70 microns, preferably above 0.1 micron but not exceeding 30 microns, particularly preferably 0.1 to 20 microns. The use of a carrier containing at least 80% by weight of particles with a size in the above-specified range is recommended.

Various mechanical pulverizing means already known in the art may be used to produce particles of the carriers used in the process of the invention. For the production of particles having an average particle size of less than 1 micron, it is rather advisable to prepare a solution of the carrier compound, e.g. prepare a solution in an alcohol of anhydrous magnesium or manganese halide, and mix the solution with an organic precipitant incapable of dissolving such halide, such as hydrocarbons or halogenated hydrocarbons to thereby reprecipitate it as fine particles. As such alcohol, lower aliphatic alcohols such as methanol, ethanol, propanol, butanol, hexanol and noctanol can be exemplified; the examples of such hydrocarbons are pentane, heptane, kerosene, benzene, toluene, and xylene; and examples of the halogenated hydrocarbons are carbon tetrachloride, chloroform, dichloroethane, chlorobenzene, bromobenzene and chlorotoluene.

The average particle size of carrier particles prepared by this procedure usually reaches 0.1 to 1 micron, a size difficult to obtain by the ordinary mechanical pulverizing means.

For pre-treating the anhydrous metal halide with the electron donor in the invention, any means can be employed which is capable of bringing the metal halide into contact with the electron donor which is either liquid or gaseous under the treating conditions, in the substantial absence of water. For instance, the electron donor which is liquid or gaseous at the pre-treating temperatures and pressures can either be directly contacted with the particles of the metal halide, or can be contacted with the particles suspended in an organic medium such as hexane, kerosene, or benzene. According to another pre-treating method, an electron donor which is solid at the pretreating temperatures and pressures is dissolved into an organic liquid medium capable of dissolving the electron donor, and then contacted with an anhydrous metal halide. Accordingly, the pre-treatment with an electron donor which is liquid or gaseous under the pre-treating conditions, as used in the present invention, also includes the above-mentioned embodiments.

Preferably, the pre-treating temperature is not higher than the thermal decomposition temperature of the dihalide of the divalent metal. A suitable temperature can usually be selected within the range of -50 to +300 C., preferably room temperature to 200 C., and more preferably 40 to C. The pre-treating time may be one which will provide a sufficient contact between the anhydrous metal halide and the electron donor, and is not particularly restricted. Usually, it is from 5 minutes to 5 hours depending upon such factors as the contacting means and the electron donor used. A long time contact is not necessary, although it is not disadvantageous.

It is not known how the electron donor coordinated, or presumed to be cordinated, with the carrier acts in the fixing of a transition metal halogen compound to form a highly active, supported catalyst. But the following conjecture may hold good. In view of the fact that the results intended by the present invention can hardly be achieved, as will be shown later in the examples and comparative examples, when the polymerization of olefins is conducted (1) by using a catalyst component prepared by reacting a non-pretreated carrier with a transition metal halogen compound, (2) by using a catalyst component prepared by reacting a carrier with a transition metal halogen compound in the mere presence of an electron donor, or (3) by using, in the presence of an electron donor, a catalyst component prepared by reacting a transition metal halogen compound with a carrier which is not pre-treated with an electron donor, it is presumed that an interaction occurs among the metal halide particles, electron donor and transition metal halogen compound. In the case of an ester as the electron donor, the presence of a coordination bond between the electron donor and the carrier is confirmed from the fact that there is a shift in the position of the characteristic absorption band in the infrared spectrum.

The electron donor used in the invention is liquid or gaseous under the pre-treating conditions (including cases where it is capable of becoming liquid or gaseous), and is selected from the group consisting of aromatic carboxylic acids, aliphatic carboxylic acids, alkyl esters of aliphatic carboxylic acids, alkyl esters of aromatic carboxylic acids, aliphatic ethers, cyclic ethers, aliphatic ketones, aromatic ketones, aliphatic aldehydes, aliphatic alcohols, aromatic alcohols, aliphatic acid halides, aliphatic nitriles, aromatic nitriles, aliphatic amines, aromatic amines, aliphatic phosphines and aromatic phosphines. Among these electron donors, C C saturated or unsaturated aliphatic alcohols, particularly monohydric or polyhydric aliphatic alcohols, C -C aromatic alcohols; alkyl esters of C C saturated or unsaturated aliphatic carboxylic acids which may have a substituent, especially'a halogen atom, and C -C saturated or unsaturated aliphatic alcohols, particularly monohydric or dihydric aliphatic alcohols; alkyl esters of aromatic carboxylic acids between C -C aromatic carboxylic acids, especially C -C monovalent or divalent aromatic carboxylic acids, which may have a substituent, especially a lower alkyl group, and C C saturated or unsaturated aliphatic alcohols, especially monohydric or dihydric aliphatic alcohols; C1C 15, especiallyC -C saturated or unsaturated aliphatic carboxylic acids; C -C aromatic carboxylic acids which may have a substituent attached to the aromatic nucleus, especially C -C monovalent or divalent aromatic carboxylic acids which may have a lower alkyl group as a substituent; and, pyridines which may have a substituent, especially one selected from lower alkyl groups and vinyl groups, attached to the nuclear carbon are preferred. As the aliphatic ethers, C C preferably C -C aliphatieethers; as the cyclic ethers, C -C cyclic eth'er's;preferably I1 cyclic monoor di-ether; as the aliphatic ketones,.,C-C preferably C -C aliphatic ketones; as the-"aromatic aldehydes, C7-C12 aromatic aldehydes, preferably benzaldehyde; as the aliphatic nitriles, C C aliphatic nitriles, preferably acetonitrile; as the aliphatic "amines, C C preferably C -C aliphatic amines; and as the aromatic amines, C C preferably C C aromatic amines are cited. Specific examples of these electron donors are aliphatic carboxylic acids such as acetic acid, propionic acid, valeric acid and acrylic acid; aromatic Qcarboxylic acids such as benzoic acid and phthalic acid; aliphatic carboxylic acid esters such as methyl formate; dodecyl formate, ethyl acetate, butyl acetate, vinyl acetate, methyl acrylate, octyl lactoate, ethyl laurate and octyl laurate; aromatic carboxylic acid esters such as methyl benzoate, ethyl berizoate, octyl paraoxybenzoate and dioctyl phthalate; aliphatic ethers such as ethyl ether, hexyl ether, allylbutyl ether and methyl undecyl ether; cyclic ethers such as tetrahydrofuran, dioxane and trioxa'ne; aliphatic amines such as methyl amine, diethyl amine, tributyl amine, octyl amine and dodecyl amine; aromatic amines such as pyridine, aniline and naphthyl amine; aliphatic ketones such as acetone, methyl isobutyl ketone, ethyl butyl'ketone and dihexyl ketone; aromatic ketones such as acetophenone; aliphatic aldehydes such as propionaldehyde; aliphatic alcohols such as methanol; ethanol, isopropanol, hexanol, 2-ethyl hexanol, octanol and dodecanol, aromatic alcohols such as benzyl alcohol and methyl benzyl alcohol; aliphatic nitriles such as acetonitrile, vale'ronitrile and acrylonitrile; aromatic nitrile such as'benzonitrile and phthalonitrile; aliphatic acid amides such as acetamide; and phosphines such as triethyl phosphineand triphenyl phosphine.

The pre-treated solid particles are heat-treated together with a halogen compound of a transition metal selected from the group consisting of tetravalent titanium metal, tetravalent yanadium.metal and pentavalent vanadium metal, whichfis' liquidunder the heat-treatment conditions to thereby bond the halogen compound to the surfaces of the solid particles This fixing of the halogen compound to the surifaces of the pretreated solid particles may be effected iii a manner similar to previous proposals. For instance, th is can be effected by heating the pre-treated metal halideflp'articles "together with the transition metal halogen compoundp Specific examples of the titanium or vanadium halogen compounds which are liquid under the treating conditions are halogen :compounds of tetravalent titanium such as titanium tetrachloride, titanium tetrabromide, titanium ethoxy trif chloride, titanium diethoxy dichloride and titanium dibutoxy dichloride; halogen compounds of tetravalent vaiiadiurn'such as vanadium tetrachloride; and halogen compounds gof pentavalent vanadium such as vanadiumtoxytrichloride; Preferably, halogen compounds of tetravale 'ta'niumgparticularly titanium tetrachloride, are used. i

For suporting the transition metal halogen compound on the pre-treated particles of the divalent meal dihalide, they are heat-treated in contact with each other at a temperature of to; 300 (3., preferably 70to 140 C. This treatment is performedin an iriert gas atmosphere free from oxygen and water. After contacting the transition metal halogen compound; with tlie pre-treated particles of the divalent metal dihalide at the predetermined temperature and for the predetermined time, a large excess of the transition metal halogen compound is removed by filtration or decantation, preferably followed by washing with a fresh transition metal halogen compound. Subsequently, washing with a suitable inert solvent such as hexane, heptane or kerosene is efiected to remove free transition metal halogen compound not supported on the metal halide.

In the supporting procedure, if the halogen compound is liquid, particles of the divalent metal dihalide are immersed in the halogen compound to elfect contact between them. If desired, the halogen compound may be repeatedly contacted with the carrier by putting the carrier into an extracting tube such as a Soxhlet extractor, and refluxing the halogen compound through the tube.

In the supporting of the transition metal halogen compound on the pre-treated divalent metal dihalide according to the invention, it is not preferable to use the transition metal halogen compound in a form diluted with a solvent capable of dissolving it. If, for instance, a saturated hydrocarbon is used as the diluting solvent, a complex formed by the interaction of the transition metal halogen compound and the electron donor, only sparingly soluble in the hydrocarbon, is likely to envelop the surface of the metal halide, and make it impossible to prepare an effective catalyst.

When the transition metal halogen compound supported on the divalent metal dihalide pre-treated with the electron donor is used as a catalyst component, it is made into a suspension in an inert solvent such as hexane, heptane or kerosene, or it is made into a solid powder by volatilizing the washing liquid in a dry inert gas stream or under reduced pressure.

The electron donor coordinated, or presumed to be coordinated, with the divalent metal dihalide by the pretreatment according to the invention, when encountered with the transition metal halogen compound, reacts with it or forms a complex together with the transition metal halogen compound, and most of it comes off from the surface of the solid divalent metal dihalide to be dissolved in the transition metal halogen compound which is present in excess. Careful examination of the behavior of the electron donor by an infrared absorption spectrum indicates that after reaction with the transition metal halogen compound, it comes off from the solid divalent metal dihalide completely or mostly.

When a divalent metal dihalide having no electron donor coordinated therewith is washed with a solvent after reacted with the transition metal halogen compound, the transition metal halogen compound is not at all fixed thereon, or only a trace of the transition metal halogen compound considered to remain fixed owing to insufiicient washing is detected. Such catalyst component exhibits no polymerization activity or gives only a minor amount of a polymer.

It is thus presumed that the electron donor serves as an agent for fixing the transition metal halogen compound on the divalent metal dihalide. Usually, when the transition metal halogen compound reacts with the divalent metal dihalide pre-treated .with an electron donor, substantially all of the electron donor is taken off, and is not present in the final carrier-supported catalyst, or remains only in a negligible amount.

Generally, an electron donor of various kinds is added to an olefin polymerizing catalyst comprising a transition metal halogen compound and an organometallic com! pound for the purpose of promoting the polymerization activity, regulating the molecular weight distribution and also regulating the molecular weight. In the process of the. invention, too, the electron donor which may remain in the metal halide owing to insufficient reaction or insuflicient washing would exhibit almost the same elfect. Hence, it is not necessary to remove the electron donor complete ly unless it is to be particularly avoided, and if desired, a suitable amount of the electron donor may be present in the final catalyst so as to achieve the above-mentioned objects.

The amount of the electron donor used in the invention to pre-treat the divalent metal dihalide is not particularly restricted, but it is preferable to use 6-10 mol or so of the electron donor coordinated or presumably coordinated with the divalent metal dihalide per mol of the divalent metal dihalide. The use of an excessive amount of the electron donor will only result in an unbeneficial reaction with the transition metal halogen compound to form, for instance, an alkoxide of titanium. When, therefore, excess electron donor is present, it is advisable to add excess transition metal halogen compound, or volatile free electron donor by heating and thereafter to support the transition metal halogen compound on the pro-treated carrier particles.

It is sufficient that the amount of the transition metal halogen compound to be supported onto the pre-treated particles of the divalent metal dihalide is about 0.01 mmol to 5 mmols per gram of the pre-treated divalent metal dihalide. If desired, up to mmols of the halogen compound may be used.

According to the present invention, the polymerization of olefins is conducted by using a catalyst comprising the transition metal halogen compound fixed to the pre-treated divalent metal dihalide and an organometallic compound selected from the group consisting of organoaluminum compounds and alkyl zinc.

As these known organometallic compounds, organoaluminum compounds expressed by the general formulae R Al, R AlX, RAIX R AlOR, RAl(OR)X and R Al X (wherein R is an alkyl or aryl group, and X is a halogen atom) and dialkyl zinc expressed by the general formula R Zn (wherein R is an alkyl group) are cited. Specific examples of the preferable organometallic compounds are triethyl aluminum, tripropyl aluminum, tributyl aluminum, diethylaluminum chloride, diethyl aluminum bromide, diethylaluminum ethoxide, diethylaluminum phenoside, ethylaluminum ethoxychloride, ethylaluminum sesquichloride, diethyl zinc and dibutyl zinc.

According to the process of the invention, the polymerization and/or copolymerization of olefins is performed by using a particular type Ziegler catalyst comprising the transition metal halogen compound bonded by the heattreatment to the surfaces of the solid particles of the divalent metal dihalide which are pre-treated with the electron donor, as hereinbefore described.

The olefins to be polymerized according to the present invention include known olefins polymerizable or copolymerizable with the Ziegler-type catalyst, such as ethylene, propylene and butene.

The concentration of the transition metal halogen compound supported on the carrier which is used in polymerizing olefins is preferably 0.005 to 10 g. per liter of the solvent used in the polymerization system, while the concentration of the organometallic compound is preferably 0.01 to 50 mmols on the same basis.

A mere combination of the transition metal halogen compound and the divalent metal dihalide treated or not treated with the electron donor exhibits no polymerization activity towards olefins. In the preparation of the catalyst according to the invention, it is necessary to add the organometallic compound to the transition metal halogen compound supported on the pre-treated metal halide or vice versa.

The polymerization reaction of olefins using the catalyst of the invention is carried out in the same manner as in the known polymerization reactions using the ordinary Ziegler-type catalyst.

These operations need to be performed in a substantially oxygenand water-free condition. A suitable inert solvent such as hexane, heptane or kerosene is used. The catalyst of the invention is put into the solvent, and at least one olefin is fed thereinto to effect its polymerization. The polymerization temperature is to 200 C.,

preferably 60 to 180 C., and the polymerization is preferably carried out under elevated pressure. The pressure ranges from atmospheric pressure to kg./cm. especially from 2 to 60 kg./cm. In the polymerization of ethylene with the catalyst system of the invention, the molecular weight of the polymer can be controlled to some extent by varying the polymerization conditions, such as the polymerization temperature and the molar ratio of the catalyst. The addition of hydrogen to the polymerization system, however, is effective, and the use of a great quantity of hydrogen gives a waxy polymer.

The advantage of the invention is that polyolefins having a far higher melt index can be obtained than in the case of using a catalyst component prepared by support ing the transition metal halogen compound on the carrier without the use of the electron donor. Moreover, as compared with the catalyst system without a carrier, the catalyst system of the invention gives an increased yield of polyolefins per unit weight of the transition metal. In the case of the slurry polymerization, the resultant polymer has a very high bulk density, and therefore, the yield of the polymer per unit weight of the solvent increases. Furthermore, it becomes easy to discharge and transport the polymer. An additional advantage is that as the resultant polymer contains a very small amount of the transition metal compound, almost no practical disadvantage occurs in the shaped articles from the polymer even if the transition metal compound is not inactivated. When it is desired to remove the carrier, the polymer is treated with water or alcohol, as the divalent metal dihalide is soluble in water or alcohol.

The invention will further be described with reference to the following examples.

EXAMPLE 1 Commercially available anhydrous magnesium chloride was calcined in a steam of nitrogen at 300 C. for 6 hours. The infrared absorption spectrum of the heattreated magnesium chloride did not indicate the presence of absorption bands based on water or crystallization or hydroxyl groups either. The magnesium chloride (9.5 g.) was added in a nitrogen atmosphere to a suspension of 10 mmols of absolute methanol in anhydrous hexane, and heat-treated for 30 minutes at 50 C., followed by drying under reduced pressure. The analysis thereof showed that this magnesium chloride has a composition MgCl MeOH (Me is a methyl group). The infrared absorption spectrum of this compound clearly showed the presence of an absorption band of methanol, but there was no appreciable absorption band based on Water of crystallization.

This magnesium chloride was suspended into titanium tetrachloride, and stirred at C. for 1.5 hours. The reacted suspension was filtered while hot, and washed with refined hexane until there was no appreciable presence of chlorine in the washing liquid. (The foregoing operations were all performed in a nitrogen atmosphere.) The so prepared carrier-supported catalyst component contained a titanium chlorine compound which is equivalent to 12 mg. of titanium per gram of the carrier. The absorption band based on the methanol which had been observed before reaction with titanium tetrachloride completely disappeared after the reaction.

A 3-liter autoclave was charged with l-liter of hexane as a polymerization solvent, and then with 200 mg. of the carrier-supported catalyst component and 3 mmols of triisobutyl aluminum, and was heated to 90 C. On addition of 3.5 kg./cm. of hydrogen, ethylene gas was continuously fed and polymerized While the total pressure was being maintained at 7 kg./cm. The two-hour polymerization yielded 280 g. of a white polyethylene having a bulk density of 0.3 and a molecular weight of 50,000. The yield corresponds to 1400 g. per gram of the carrier-supported catalyst component and 5600 g. per mmol of titanium.

9 COMPARATIVE EXAMPLE 1 COMPARATIVE EXAMIPLE 2 Commercially available anhydrous magnesium chloride was heated at 300 C. for 6 hours. The obtained magnesium chloride was heated together with titanium tetrachloride in the same manner as in Example 1, with the result that the chlorine compound of titanium equivalent l phere. The heat-treated anhydrous magnesium halides were suspended into dry hexane in a nitrogen atmosphere, and while stirring at a high speed, stoichiometric amounts of absolute alcohols were added to form a magnesium halide containing the alcohol at various ratios as indicated in Table 1. The alcohol-containing magnesium halide was suspended in various transition metal halogen compounds indicated in Table 1 and stirred at 110 C. for 1.5 hours. The reacted suspension was filtered while being hot, and washed with refined hexane until there was no appreciable presence of halogen in the washing liquid, followed by drying. (All the foregoing operations were performed in a nitrogen atmosphere.) Ethylene was polymerized under the same conditions as in Example 1 except using 200 mg. of the carrier-supported catalyst component and mmols of triisobutyl aluminum. The results are given in Table 1.

TABLE 1 Transition metal halogen compounds Kind and mole of alcohol Amount Yield of coordinated with one mole fixed polyethylof MgClz Kind (mg/g ene (g.)

CHaOH TiCl; 16 273 CHaOH TiBti 14 206 0113011 Ti(OEl;) C1 15 228 CHgOH Ti(nB110)zClg 19 207 CHaOH VCli 21 138 CHaOH VOCls 25 141 2CH3OH T1312 21 297 0211.011 TiCh 0. 2 4

17115 02115011 TiCh 2 210 oznfiorr TiCh s 315 CZH5OH TiCh 24 293 fiCzHsLH 'IlCh 59 301 CHZ=CHCH2OH TlCli 14 196 CH2=CHCH2OH V014 18 142 IICxHnOH TlCh 16 254 CeHsCHzOH VOCla 18 103 110121125011 TlClg 15 246 12H250H 'IiBn 14 200 onion Ti(OEt)Cl3 s 171 EtOH T1014 14 221 iPrOH TiBri 14 194 3CaHi70H T1014 27 275 0121125011 v01. 16 122 CHaOH T101 14 235 02115011 TKOHBLI) C1 15 221 C3H17OH Tl(OnBu) C12 18 206 C12H25OH T11311 14 215 l 0r less.

Norm-Et stands for an ethyl group; Bu, a butyl group; and Pr, a propyl group. These abbreviations have v the same meanings hereinafter. to 0.2 mg. of titanium Wassupported per gram of the carrier.

Ethylene was polymerized for 2 hours at 90 C. in the same manner as in Example 1 using 200 mg. of the so EXAMPLES 28-32 Ethylene was polymerized in the same manner as in Example 1 using various aluminum or zinc compounds indicated in Table 2 instead of the triisobutyl aluminum b a carrier-Supported Catalyst Component and 3 employed in Example 1. The results are shown in Table 2.

TABLE 2 Yield of polyethylene G./g. of the Organometallic compounds earrier- Melt supported index of Amount catalyst poly- Kind (mmol) G. component ethylene Exam le:

28 (CzHmAlCl 3 215 1,080 0.4 29.. (C2Hs)2AlBr 3 208 1, 040 0.4 30 (CgHshAlOCzHs 3 142 710 0.9 3l C2HaAl.OC2H5.Gl 3 158 790 0.7 V 32..-; (C H Zn 3 186 930 0.5

mmols of triisobutyl aluminium. Polyethylene was ob- EXAMPLE 33 tained in 5 g. yield, which corresponds to 25 g. pergram of the carrier-supported catalyst component.

' EXAMPLES 2 TO 27 AND COMPARATIVE V I EXAMPLE 3 Commercially available anhydrous magnesium halides were calcined for 3 hours at 600 C. in a nitrogen atmos- 1 1 was then filtered, and washed with refined hexane until there was no appreciable presence of chlorine in the washing liquid. The resultant solid carrier supported catalyst component contained a chlorine compound of vana- 12 This manganese chloride was suspended into titanium tetrachloride, and stirred for 1.5 hours at 110 C. Thereafter, the reacted suspension was filtered while being hot, and washed with refined hexane until there was no appredium equivalent to 21 mg. of vanadium fixed thereto. ciable presence of chlorine, followed by drying. (All the Ethylene was polymerized in the same manner as in Exforegoing operations were conducted in a nitrogen atmosample 1 using 200 mg. of the carrier-supported catalyst phere.) The resultant carrier-supported catalyst comcomponent and 2 mmols of triethylaluminum. Some 213 g. ponent contained the chlorine compound of titanuim of polyethylene having a molecular weight of 45,000 equivalent to 14 mg. of titanium per gram of the carrier. were obtained. The absorption band based on methanol which had been EXAMPLE 34 observed before the reaction with the titanium tetrachloride completely disappeared after the reaction.

A 500 cc. flask was charged w th 250 cc. of refined kero- A 3-liter autoclave was charged with one liter of kero- Sena, and thoroughly purged Wlth h The earner sene, 200 mg. of the so prepared carrier-supported catalyst supported catalyst component p pa 1n Examplel component and 4 111111011 of triisobutyl aluminum, and 55-) and 2 mmols of methyl aluminum Were added and heated to 80 C. Hydrogen was introduced to a pressure the temperature was ra1sed to 70 C. Ethylene was then of 3.5 y e and ethylene gas was continuously f d added l P I and polymeflled for 2 while maintaining the total pressure at 7 kg./cm. The hours Without e addltlon of hydrogen to glve 72 of polymerization of ethylene was performed for 2 hours to P y y havlhg than one Y P P 1000 give 254 g. of a white polyethylene having a melt index carbon atoms and having a molecular weight of 650,000. f The yield f the polyethylene corresponded to 1270 g. per gram of the carrier-supported catalyst com- EXAMPLE 35 ponent and 4380 g. per mmol of the titanium.

Commercially available anhydrous manganese dichloride was calcined at 400 C. for 3 hours in a nitrogen gg ;g,f FR ARATIVE stream. The infrared absorption spectrum of this heattreated manganese chloride did not show the presence of An anhydrous manganese halide was heated at 400 absorption bands based on water of crystallization or hy- C. for 3 hours under a nitrogen stream, and then susdroxyl groups. The manganese dichloride (12.6 g.) was pended into heptane, followed by addition of an alcohol. added in a nitrogen atmosphere to a suspension of 50 In the same manner as in Example 35, this alcohol-conmmols of absolute methanol in anhydrous hexane, and taining manganese halide was reacted with a transition the mixture was heated for 30 minutes at 40 C., folmetal halogen compound to thereby fix the transition lowed by drying under reduced pressure. The analysis of metal halogen compound onto the carrier. Ethylene was the resulting product showed that it had a composition polymerized under the same conditions as in Example MnCl /zMeOH. The infrared absorption spectrum of 35 using 200 mg. of the so prepared carrier-supported this compound clearly showed the presence of an absorpcatalyst component and an alkylaluminum or alkyl zinc of tion band of methanol, but an absorption band based on an amount indicated in Table 3. The results are also water of crystallization could not be seen. shown in Table 3.

TABLE 3 Transition metal halogen compounds Yield of Man- Kind and mole of alcohol Amount polyganese coordinated with one mole fixed Organo-metalllc ethylene halide of manganese halide Kind (mg/g.) compounds mol (g.)

Comparative 13111111111114 M11011 Not used T1011 0.2 E0111 3 1 Example:

33 M11011 01111011 T1011 19 EtzAlBr 3 10s 37 M11011 01111011 T1011 19 191111 110111 3 99 3s M11011 01111011 T1011 19 (EtO)AlEtCl 3 72 39 M11011 011150151 T1011 19 E0111 3 268 40 M11011 01111011 T1011 19 1911211 3 q 93 41." M11012 C2H5OH TlB14 17 EtaAl 3 195 42... M11011 01115011 Ti(OEt)Cl 18 1911111 3 197 43.-. M11011 01111011 T1 o11Bu)1011 17 191111101 4 88 44". M11011 01115011 V011 21 EtaAl 3 131 45 M1101, 01111011 V0011 23 191111101 3 Comparative 1 p Examples M11011 01115011 T1011 0.2 EtaAl 3 1 Example: 1

46 MIIC]: CzH5OH T1011 1.5 ElZaAl 3 68 47 MnCh 1 301115011 T1011 20 1911111 3 186 42 MnCh lPrOH T1011 5 1911111131 3 112 011110111011 T1011 14 191111110111 3 94 0H1=0H0H1oH V011 19 (EtO)AlEtCl 3 81 nBuOH T1011 9 E0211 3 139 l'lCsHuOH TlBl'4 16 EtaAl 3 187 C12H25OH T1011 15 iBllaAl 3 195 0111115011 T1(0Bu)011 19 191111101 3 93 01110151 T1011 12 1911111 3 195 30111011 T1011 32 113111111 3 296 01111011 T1311 13 EtzAlBr 3 .99 ZCZH5OH V014 22 Et .5AlCl1.' 3 72 110111115011 (EtO)TiCl 4 EtzZn 3 52 11011HH V0011 21 (EtO)A1EtCl 3 48 11-01H110H T1011 14 19111 .101 3 82 1101111110131 T1 0Et)011 13 1913111 3 177 11-01H110H V0011 21 EtzZn 3 37 13 EXAMPLE 65 A 500 cc. flask was charged with 250 cc. of refined kerosene, and then thoroughly purged with nitrogen. The carrier-supported catalyst component (0.5 g.) prepared in Example 35 and 2 mmols of triethyl aluminum were added, and the temperature was raised to 70 C. Ethylene was added at atmospheric pressure without adding hydrogen, and'the polymerization of ethylene was performed for 2 hoursfto give 82 g. of polyethylene having a bulk density of 0.27, a molecular weight of 720,000 and less than one methyl group per 1000 carbon atoms.

EXAMPLE 66 Commercially available anhydrous magnesium chloride was pulverized in a nitrogen atmosphere, and dried while passing a nitrogen stream for 2 hours at 600 C. This magnesium chloride (9.5 g.-100 mmols) was suspended into 40 cc. of anhydrous hexane, and while stirring 50 mmols of dried and refined methyl acetate were added. After refluxing for one hour, hexane was removed by heating in vacuo. The infrared absorption spectrum of the obtained solid indicated that there was an absorption band of carbonyl shifted to 1705 cm.- (red shift), as compared with an absorption band of free methyl acetate at 1742 cmr and it was confirmed that methyl actate was coordinated with magnesium chloride. Furthermore, the elemental analysis indicated that it has a composition MgCl /zCH COOCH Five grams of magnesium chloride pre-treated with methyl acetate were suspended into 40 cc. of titanium tetrachloride, and they were reacted for one hour at 130 C. The reaction product was filtered while the reaction system was still hot to thereby separate a solid portion. The filtrate was cooled and there yellow crystals which were confirmed by the infrared absorption spectrum a complex of titanium tetrachloride and methyl acetate were obtained. The solid portion was thoroughly washed with anhydrous hexane and then dried to remove the contained hexane. The infrared absorption spectrum of the so obtained solid compound did not at all show the presence of an absorption band based on methyl acetate. The chemical determination of titanium showed that this solid compound fixed the chlorine compound of titanium equivalent to 18 mg. of titanium per gram thereof.

A 2-liter autoclave was charged with one liter of refined kerosene, 3 mmols of triethyl aluminum, and 150 mg. of said solid compound, and heated to 90 C. Hydrogen was added to a pressure of 3.5 kg./cm. and ethylene was introduced continuously while maintaining the total pressure at 7 kg./cm. The polymerization of ethylene was carried out for 2 hours to give 278 g. of polyethylene having a melt index of 9. The obtained polyethylene was white even without further treatment with an alcohol, for instance. The yield of the polyethylene corresponds to 1850 g. per gram of the carrier-supported catalyst component and 4930 g. per mmol of titanium.

This polyethylene had 0.11% of an ash content. The ash content was reduced to 0.005% by suspending the polyethylene into methanol and heating it for 30 minutes at 90 C. When the polyethylene is used for applications where the ash content gives adverse efiects, the ash may be removed easily by the post-treatment.

COMPARATIVE EXAMPLE 6 Five grams of magnesium chloride prepared in Example 66, without coordination of methyl acetate, were suspended in 30 cc. of titanium tetrachloride, and the suspension was heated for one hour at 130 C. A solid portion was separated by filtration, and washed thoroughly with refined hexane to remove free titanium tetrachloride. The solid portion did not contain fixed thereon a titanium compound of an amount detectable by a chemical analysis. Using this solid portion and triethyl aluminium, ethylene was subjected to polymerization in the same manner as in Example 66, but polyethylene was not formed.

COMPARATIVE EXAMPLES 7 TO 9 Using titanium tetrachloride and triethyl aluminium at the same titanium and aluminum concentrations as in Example 66, ethylene was polymerized under the same conditions as in Example 66 except that anhydrous magnesium chloride as the carrier 'was not used (Comparative Example 7); a pre-treatment reaction for supporting on the carrier was not carried out, but anhydrous magnesium chloride, titanium tetrachloride and triethyl aluminum were merely caused to be present conjointly (Comparative Example 8); and that 0.79 mmol (the same amount as employed in Example 66) of methyl acetate was caused to be present conjointly. The results are given in Table 4.

TABLE 4 Comparative Example: Yield of polyethylene (g.) 7 4.4 8 5.2 9 4.6

COMPARATIVE EXAMPLE 10 The same anhydrous magnesium chloride (9.5 g.) as used in Example 66 was suspended into cc. of titanium tetrachloride. Without prior coordination with the magnesium chloride, 50 mmols of methyl acetate was added to this system and a solid catalyst component was prepared in the same manner as in Example 66. The titanium compound equivalent to only 0.3 mg. of titanium per gram of the carrier-supported catalyst component was fixed. Ethylene was polymerized using 150 mg. of this catalyst and 3 mmols of triethyl aluminum under the same conditions as in Example 66. Only 8 g. of polyethylene were obtained.

COMPARATIVE EXAMPLE 11 One gram of magnesium chloride prepared in Example 66 was suspended in 5 cc. of hexane, and 0.2 mmol of triethyl aluminum was added. The system was stirred for one hour at room temperature, and hexane was removed under vacuum. Titanium tetrachloride (5 cc.) was added, and the mixture was heated for 30 minutes at C. while stirring. The reaction product was filtered to separate a solid portion. Free titanium tetrachloride was washed with refined hexane. The titanium compound equivalent to 29 mg. of titanium per gram of the dried carrier-supported catalyst component was fixed. Using 150 mg. of this catalyst and 3 mmols of triethyl aluminum, ethylene was polymerized under the same conditions as in Example 66. Only 23 g. of polyethylene having a melt index of 0.01 were obtained. The yield corresponds to 150 g. per gram of the carrier-supported catalyst component and 260 g. per mmol of titanium.

COMPARATIVE EXAMPLE 12 Commercially available magnesium chloride hexahydrate (MgCl '6H 0) was placed in quartz tube, and heated in an electric oven. It began to melt at a temperature in the vicinity of 110 C. Heating was continued with the electric oven maintained at 280 C. A great quantity of hydrochloric acid was generated, and then a solidified mass of magnesium hydroxychloride was formed. The solid mass 'was further heated at 280 C. for 5 hours, and then pulverized. Five grams of the pulverized solid mass was suspended into 40 cc, of titanium tetrachloride, and stirred for 1.5 hours at C. A solid portion was separated by filtration, and free titanium tetrachloride was removed with refined hexane. It was found that the titanium compound equivalent to 6 mg. of titanium was fixed per gram of this solid. Ethylene was polymerized under the same conditions as in Example 66 using mg. of this solid catalyst component and 3 mmols of triethyl aluminum. Some 125 g. of polyethylene having a molecular weight of 60,000 were obtained. The yield corresponds to 830 g. per gram of the carrier-supported catalyst component and 6640 g. per mmol of titanium. This catalyst gave as high a yield of polyethylene based on the transition metal as in the case of using a catalyst within the scope of the invention, but as the yield of polyethylene based on the carrier-supported catalyst component was low, an ash content of the final polyethylene reached 0.25%.

The polyethylene was suspended into methanol to posttreat it at 90 C. The ash content was 0.13% even after the completion of the post-treatment. The magnesium hydroxychloride was insoluble in water or alcohol, and most of the components removed by the post-treatment was the aluminum component. Hence, when this carrier is used, the clogging of a screen pack at the time of pelletizing, the rust of a mold at the time of molding, or the fish eye of polyethylene occur, and it is impossible to produce a polymer which is fully satisfactory when used in applications in which the ash content is of a great concern.

COMPARATIVE EXAMPLE 13 In the same way as in Example 66, 5 g. of anhydrous magnesium acetate were reacted with 40 cc. of titanium tetrachloride. The titanium compound equivalent to 6 mg. of titanium per gram of the carrier was fixed. Ethylone was polymerized under the same conditions as in Example 66 using 150 mg. of this carrier-supported catalyst component and 3 mmols of triethyl aluminium. Only 64 g. of polyethylene having a bulk density of 0.10 were obtained. The yield corresponds to only 430 g. per gram 1 6 EXAMPLE 67 Anhydrous manganese chloride was dried for.2' hours at 500 C. in a nitrogen stream. One mol of this anhydrous manganese chloride was suspended into cc. of dried hexane. On addition of 1 mol of ethyl acetate, the system was refluxed for one hour. The infrared absorption spectrum of the pre-treated solid compound free of hexane indicated the presence of a shifted absorption band based on the coordinated ethyl acetate. Five grams of this solid compound was suspended into 50 cc. of nbutoxy titanium trichloride, and heated at C. for one hour. After the completion of pre-treatment reaction, a solid portion was separated by filtration, followed by thorough washing with refined hexane to remove free nbutoxy titanium trichloride, and drying. The titanium compound equivalent to 17 mg. of titanium per gram of this solid portion were fixed. The infrared absorption spectrum of this solid did not indicate the presence of an absorption band based on ethyl acetate.

Ethylene was polymerized under the same conditions as in Example 66 using mg. of the above-mentioned carrier-supported catalyst component and 3 mmols of triethyl aluminum. Some 225 g. of polyethylene having a melt index of 4 were obtained.

EXAMPLES 68 TO 194 AND COMPARATIVE EXAMPLES 14 TO 19 In the same manner as in Example 66, various metal halides were pre-treated with esters, organic acids and amines, followed by reaction with transition metal halogen compounds to prepare catalyst components supporting the transition metal halogen compounds. Ethylene was polymerized in the same way as in Example 66 using the so prepared catalyst components and triethyl alumi- 35 of the carrier-supported catalyst component. num, The ults are given in Table 5.

TABLE 5 Transition metal halogen compounds Amount fixed (mg. per Magnegram of the Yield of siurn Mole of electron donor used to pro-treat supported polyethyhalide one mole of magnesium halide Kind catalyst) lene (g.)

Example:

es MgClz 11000011, T1014 10 195 69 MgClz 5 noooon, T113" 12 192 Comparative Example 14.-- MgClz 01130000211 T101} 3 a 01230000211, T1014 1 3g 0H COO02H T1014 21 1 261 0H30OO01H TiBri 20v 182 0H30OO02H Ti(OEt) C1 19 209 01130000211 Ti(OnBu)20l2 21 177 CH3COOC2H5 Volt 23 138 0H300O0zH V001 22 125 601130000211 T101 24 257 02H500004H T101 21 W 79 MgCl 00130000211 T101 16 213 CChCOOCzH; Ti (OEt) C1 19 195 HCOOClZHzs T101 17 190 11000012112 V014 21 141 0H =0H(0H2)5COOC1H T1014 19 203 O12H25COOCH3 Ti0l4 19 191 CizHnCOOCHa Ti(OEt)C1i 18 188 0i2Hz COO0H20H=CH2 T101 18 179 C12H25COOCHZCH=CH2 V0l 24 138 12H25C00C12 2s TiCh 18 198 C12H25COOC12H25 V0013 23 136 1 TiOl 4 157 Mgml To oooon L11 10 j @ooocnrm 7 TABLE 5-Cont1nued Transition metal halogen compounds Amount fixed B D Magnegram of the Yield 01 slum Mole of electron donor used to re-treat supported polyethyhalide one mole oi magnesium halide Kind catalyst) n6 Example:

1 T1011 4 151 92 MgCh 16 CH; O0H1 1 T101 4 150 93 M3011 16 CH 0 0 O 012E111 1 T101 6 163 94 M801: 10 COOCgHn 1 T101 10 126 95 MgCl: 3 0H1000H Comparative Example 15... M801: 1101111000131 2 2 Example:

96 MgCl: 10111100011 T101 38 mCH1C 0 OH T101 4 n0 H70 0 0H T1011 18 203 n0 H O OH T1811 178 nCaHzC O OH 'll(OEt) 01; 19 186 n0 H 0 O OH T1(O11Bl1)10h 20 169 110 151 0 0 OH V011 22 144 110111100011 V0 011 23 141 60111100 OH T1014 51 285 0H1=0H(0Ha)100 OH T1(OEt)Cl 18 182 nCnHasC O OH T1011 21 166 nCHHaC O OH V011 18 134 C O OH T1011 18 156 109 M3011 0H 0 0 OH T101 18 162 110 M301: 0 0 0H T10l1 17 142 0 O OH 1 Comparative Example 10... MgCh 0mm 3 1 Example:

111 M 01: 0mm T101 1 Ll; CBH'N T101 33 150 01H1N TlBn 136 0 HN TigOEt) 0h 20 124 01H1N T1 OnBl1)a0h 35 111 0 H N V011 41 106 01H1N V0011 44 92 601H|N T1011 48 146 i 1 T1011 11 14a 120.. MgCla Same as above 121., MgCh T101 2 39 122 MgCh 4 m 7 TABLE {i-Qontinued A Transition metal halogen compounds Amount fixed (mg. per Magnc- J- gfa'm of the Yield of slum I M010 of electron donor used to pre-trout 4 I supported polyethyhalide one mole of magnesium halide Kind catalyst) 1on0 (g.)'

Example:

123 o T C S i I I 82 124 u c 51G (C1H9)IN T1611 1 24 125 M8012 51o Ca nN z 0 4 1 18 126 1111;014 NE T161 2 0121125000013 T1Br4 14 4 177 CHz=0H0OOCH1 Ti(OEt)0l 195 CHaCOOH T1014 13 180 C H1OOOH V00]; 18 148 04114: T101 28 120 01140000114 T1014 11 193 011300002115 T1(OEt)01 18 195 0 115000011111 TIBH 17 188 CHz=0HCOO0H V01 18 144 CISHBN T1011 HCOOCH: T1014 8 186 HCOOCH; TIBI 9 187 01140000411 T1014 0. 2- 3 Example: 7

CH1OOOC4H T101 1 49 01150000111 T101 9 208 CHaCOOCgI-Is T1314 11 182 011300002115 T1(OE1)011 10 185 011 00002111 'Ii(O11Bl1):012 11 180 0113000011215 V014 15 162 CH3COOCzH V001 17 6CH1C0OC2H; T1011 33 317 0H =0HCOO0H T101 8 213 CH1=CHCOOCH; V001; 16 151 00110000114 T1014 9 195 110000121125 T1014 11 201 H0OO012H25 V01 18 151 0111125000011: T1014 10 195 CHHZsCOOCHz V014 18 154 CH3COOCHzCHz=CH1 T101 10 185 CHI-1250000 2112 T101 11 177 -0O0CH:

0OO011H21 T101 0 4 15s M11014 Comparative Example:

18-1 M11011 Not used T101 0. 1 1 18-2 4.1 M11014 011300011 T101 .2 1 2 Example:

161 M11012 CHaCOOH 189 TABLE -Continued s Tfansition metal halogen H 4 f compounds v 1 Amount fixed I x; 1 (mg. per 1 Magnewe gram of the Yield of 5 sium Mole of electron donor used to pro-treat supported polyethyhalide one mole of magnesium halide Kind catalyst) lene (g.)

3 cmooon 'IiBn 174 CHaCOOH T1(Et0)01; 16 177 CH3COOH T1(O11B11)201a 15 178 CHgGOOH v V014 18 134 CH COOH V0014 18 120 CH3=CHCO0H T1014 14 185 l n04H 0OOH T1014 15 183 CuHuCOOH T1014 16 186 1 T1014 4 136 5 COOH 1 v 1 T1014 5 142 111 Mnpn 5 CH4 c0011 1 T1014 4 133 172 Mnon 8 -COOH 0OOH com ammenxam le 1o..- MnCh 0mm T101 0.05 0

Example: 1

17a.....f.-' MnCh 0mm T1014 1 as T1Br4 121 T1(Et0)0la 29 118 TlOnBlDCl: 25 116 V 14 35 69 V001; 37 76 T1014 42 153 011mm T1014 1 20 E HCOOCH; T1014 14 174 CHFOHOOOCH] Tl(OnBl1)201z 14 173 0 11 000031111 T1Bl4 15 011300011 T1014 17 164 C5H5N T101 38 102 CHaCOOCH; T1014 14 181 4. 0H40OOH T1014 14 173 0 H N TKOEDCI: 29 85 01- less." v

if EXAMPLES 19s To 214 Ethylene was polymerized under the same conditions components prepared in Examples n as in Enample 66 using the earner-supported catalyst 75 141, and various organoaluminum compounds or alkyl 25 26 EXAMPLE 227 g Anhydrous magnesium chloride (10 g.) calcined at g 83g i' 500 C. for one hour in a nitrogen stream was dissolved a F a into 100 cc. of absolute ethanol, and the solution was 5 i added dropwise to 400 cc. of refined chlorobenzene heated ,2 Sq 2 at 100 C. The solution was stirred for 3 hours, and the 8" 1 8 remaining ethanol was removed as completely as possible in vacuo. The system was allowed to stand to precipitate M N N N N N the resulting finely divided solid particles. The supernatant 10 E5; liquid was removed by decantation. The precipitate was repeatedly washed with hexane, and after removal of hexg ane with a nitrogen stream, it was dried. The dried solid 3 888888 particles had an average diameter of 0.5 micron. Three g Be. grams of the dried solid particles were suspended into 30 g 3- cc. of titanium tetrachloride, and stirred for one hour at g \A 120 C. At the end of the reaction, the system was filtered E 32 and washed thoroughly with refined hexane. The obtained a B solid portion was dried. It was found that the titanium a halogen compound equivalent to 42 mg. of titanium was 5:57 'q'e'a-q-q-q fixed per gram of the dried solid. 5

A 2-liter autoclave was charged with one liter of kerosene which had been sufliciently purged with nitrogen, m 40 mg. of the abovementioned solid catalyst component, '3 E5 and 3 mmols of triisobutyl aluminum. The system was g 5 heated to 90 C. and hydrogen was introduced to a presa sure of 3.5 kg./cm. Ethylene was continuously added to 3 be polymerized for 2 hours while maintaining the total 5 pressure at 7 kg. /cm. Some 222 g. of polyethylene having 5 rig a melt index of 8 were obtained. The yield corresponds a g9 to 5550 g. per gram of the solid catalyst component and 5 E, gggggg 6340 g. per mmol of titanium. Z rflrflmrarafi EXAMPLES 228 T0 233 gggg 888883 The carrier compound listed in Table 8 was dissolved 5 in the alcohol indicated in Table 8. The precipitant shown in the table was put into a glass vessel, and the system e-vs NNNNNsO was maintained at a temperature above the boiling point E of the alcohol but below the boiling point of the pre- E, E El cipitant. 40

An alcohol (concurrently acting as electron donor) soggg'w gggggg lution of the carrier compound was added dropwise with vigorous stirring to the precipitant while the alcohol was g 5 continuously removed out of the system under reduced 93 pressure to get a finely divided solid compound. The solid a particles had an average diameter of about 0.5 micron. 55 The finely divided solid particles were dried, and sus- 2.3g pended into the transition metal halogen compound shown in Table 8, and stirred for one hour at 120 C.

At the end of the reaction, a solid portion was separated *5 by filtration and washed thoroughly with refined hexane, E and dried. The so obtained carrier-supported catalyst coma ponent was combined with the organometallic compound 5; shown in Table 8 to form a catalyst. Ethylene was polymg erized in one liter of kerosene using the so obtained catalyst. The results are shown in Table 8. E

EXAMPLE 234 The grams of various magnesium or manganese halides were each dissolved into various alcohols. Various pre- E cipitants (200 cc. each) were put into a glass vessel and maintained at a temperature above the boiling point of the alcohol but below the boiling point of the precipitant. 5 An alcohol solution of the carrier was added dropwise E with vigorous stirring. The alcohol was continuously re- 0 moved from the system under reduced pressure, and finely divided solid particles were obtained. The solid particles were dried and reacted with each of the various transition metal halogen compounds (in the same manner as in Example 228 but at the temperature indicated in Table 9) given in Table 9 to thereby support the transition metal halogen compound thereon. Ethylene was polymerized in l-liter of kerosene under various conditions shown in Table 9 using this carrier-supported catalyst component and 3 mmols of triisobutyl aluminum. The results are given in Table 9.

TABLE 9 Polymer Temperature Total for reaetlon pressure Yield with the Amount of during Polymer- (g.) per gram Transition metal Ti or V supported polymerzation Polymerotthesupmetal compound fixed catalyst Hydrogen ization temperature ization ported cata- Carrier Alcohol Precipltatmg solvent compound C.) (mg./g.) (mg.) (kg./cm.z) (kg/cm. 0.) time (hr.) Yield (g.) lyst nmaImnInIousInIcIcInI-Immmmmm P MIlCl: Q. MnClI R MnBr; S MnIz We claim:

1. A process for polymerizing or copolymerizing olefins in the presence of a catalyst comprising Ziegler-type catalyst components supported on inorganic solid particles and organo-metallic compounds, which process comprises polymerizing or copolymerizing said olefins in the presence of a catalyst comprising (a) av transition metal compound supported on inorganic solid particles, obtained by pre-treating solid particlesof a dihalide of a divalent metal selected from the group consisting of magnesium, calcium, zinc, chromium, manganese, iron, cobalt and nickel with an electron donor selected from the group consisting of aliphatic carboxylic acids, aromatic carboxylic acids, alkyl esters of aliphatic carboxylic acids, alkyl esters of aromatic carboxylic acids, aliphatic ethers, cyclic ethers, aliphatic ketones, aromatic ketones, aliphatic aldehydes, aromatic aldehydes, aliphatic alcohols, aromatic alcohols, aliphatic acid halides, aliphatic nitriles, aromatic nitriles, aliphatic amines, aromatic amines, aliphatic phosphines and aromatic phosphines, said electron donor being liquid or gaseous under the pre-treating conditions, in a substantial absence of water, to prepare pre-treated solid particles of said divalent metal halide containing 10 to 6 mols of said electron donor per mol of said pre-treated solid particles and heating said pre-treated solid particles together with a halogen compound of a transition metal selected from the group consisting of tetravalent titanium, tetravalent vanadium and pentavalent vanadium, which compound is liquid under the heat-treatment conditions, to thereby bond said halogen compound to the surfaces of said pre-treated solid particles; and (b) an organometallic compound selected from the group consisting of organoaluminum compounds and alkyl zinc.

2. The process of claim 1 wherein said electron donor is a member selected from the group consisting of C -C aliphatic ethers, C -C cyclic ethers, C -C aliphatic ketones, C -C aromatic aldehydes, C -C aliphatic nitriles, C C aliphatic amines and C C aromatic amines.

3. The process of claim 1 wherein said electron donor is a member selected from the group consisting of C -C aliphatic ethers, C cyclic monoor di-ethers, C C aliphatic ketones, benzaldehyde, acetonitrile, C -C aliphatic amines and C -C aromatic amines.

4. The process of claim 1 wherein the pre-treatment with the electron donor is carried out by heating at a temperature from 50 to +300 C.

5. The process of claim 1 wherein the heat-treatment of the pre-treated solid particles and the transition metal halogen compound is effected at a temperature from 30 to 300 C.

6. The process of claim 1 wherein said electron donor is an aliphatic alcohol and said pre-treated solid particles are a precipitate formed by adding an organic precipitant selected from the group consisting of hydrocarbons and halogenated hydrocarbons incapable of dissolving said dihalide to a solution of said dihalide of a divalent metal in said aliphatic alcohol.

7. The process of claim 1 wherein said solid particles of said divalent metal dihalide have a particle size within the range of 0.05 to 70 microns.

8. A process of claim 7 wherein said particle size range is 0.1 to 30 microns, and at least by weight of said solid particles consists of particles having a size within said range.

9. A process for polymerizing or copolymerizing olefins in the presence of a catalyst comprising Ziegler-type catalyst components supported on inorganic solid particles and organo-metallic compounds, which process comprises polymerizing or copolyrnerizing said olefins in the presence of a catalyst comprising (a) a transition metal compound supported on inorganic solid particles, obtained by pre-treating solid particles of a dihalide of a divalent metal selected from the group consisting of magnesium, calcium, zinc, chromium, manganese, iron, cobalt and nickel with an electron donor selected from the group consisting of (i) C -C saturated or unsaturated aliphatic alcohols, (ii) C -C aromatic alcohols, (iii) esters of C -C saturated or unsaturated aliphatic carboxylic acids with C saturated or unsaturated aliphatic alcohols, (iv) esters of substituted C C saturated or unsaturated aliphatic carboxylic acids with C -C saturated or unsaturated alcohols wherein the substituent is a halogen atom, (v) esters of C -C aromatic carboxylic acids with C -C saturated or unsaturated aliphatic alcohols, (vi) esters of substituted C- -C aromatic carboxylic acids with C -C saturated or unsaturated alcohols wherein the substituent is a lower alkyl group, (vii) C -C saturated or unsaturated aliphatic carboxylic acids, (viii) C -C aromatic carboxylic acids, (ix) C -C aromatic carboxylic acids having a lower alkyl group attached to the aromatic nucleus, (x) pyridine and (xi) substituted pyridine wherein a substituent attached to a nuclear carbon atom is selected from vinyl and lower alkyl groups, said electron donor being liquid or gaseous under the pre-treating conditions, in a substantial absence of water, to prepare pro-treated solid particles of said divalent metal halide containing to 6 mols of said electron donor per mol of said pre-treated solid particles, and heating said pre-treated solid particles together with a halogen compound of a transition metal selected from the group consisting of tetravalent titanium, tetravalent vanadium and pentavalent vanadium, which compound is liquid under the heat-treatment conditions, to thereby bond said halogen compound to the surfaces of said pre-treated solid particles; and,

(b) an organometallie compound selected from the group consisting of organoaluminum compounds and alkyl zinc.

10. The process of claim 9 wherein said inorganic solid particles are selected from solid particles of magnesium and manganese dihalides.

11. The process of claim 9 wherein said inorganic solid particles are selected from solid particles of magnesium dichloride and manganese dichloride.

12. A process of claim 9 wherein said electron donor is a member selected from the group consisting of (i) C C saturated or unsaturated monohydric or polyhydric aliphatic alcohols, (ii) 0, aromatic alcohol, (iii) esters of C -C saturated or unsaturated aliphatic carboxylic acids with C C saturated or unsaturated monohydric or dihydric aliphatic alcohols, (iv) esters of substituted C -C saturated or unsaturated aliphatic carboxylic acids with a C -C saturated or unsaturated monohydric or dihydric aliphatic alcohols wherein the substituent is a halogen atom, (v) esters of C -C monovalent or divalent aromatic carboxylic acids with C C saturated or unsaturated monohydric or dihydric aliphatic alcohols, (vi) esters of substituted C -C monovalent or divalent aromatic carboxylic acids with C -C saturated or unsaturated monohydric or dihydric aliphatic alcohols wherein the substituent is a lower alkyl group, (vii) C C saturated or unsaturated aliphatic carboxylic acids, (viii) C7-C8 monovalent or divalent aromatic carboxylic acids, (ix) O -C monovalent or divalent aromatic carboxylic acids having a lower alkyl group attached to the aromatic nucleus, (x) pyridine, and (xi) substituted pyridine wherein the substituent attached to a nuclear carbon atom is selected from the group consisting of vinyl and lower alkyl groups.

References Cited UNITED STATES PATENTS 2,881,156 4/1959 Pilar et al. 26094.9 2,951,066 8/ 1960 Coover et al. 26093.7 3,116,274 12/1963 Boehm et al. 26094.9 3,238,146 3/1966 Hewitt et al. 26093.7 3,317,499 5/1967 Nakaguchi et al. 260--93.7 3,328,366 6/1967 Nakaguchi et al. 26094.9 3,380,981 4/1968 Miller et al. 26093.7

FOREIGN PATENTS 6714024 4/ 1968 Netherlands.

JOSEPH L. SCHOFER, Primary Examiner E. J. SMITH, Assistant Examiner US. Cl. X.R.

252-429 B, 429 C; 26093.7, 94.9 C, 94.9 E 

